Section 4 Part 03

General Specification

TABLE OF CONTENTS 3. 3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7 3.4.8 3.5 3.6 3.6.1 3.6.2 3.6.3 3.7 Rev. 0 PRECAST REINFORCED AND PRESTRESSED CONCRETE PILES .............. 2 GENERAL ................................................................................................................... 2 Scope ...................................................................................................................... 2 References .............................................................................................................. 2 Submittals ................................................................................................................ 2 Quality Assurance ................................................................................................... 2 Tolerances in Pile Dimensions ................................................................................ 2 Handling, Transportation and Storage of Piles ........................................................ 3 MATERIALS AND COMPONENTS ............................................................................. 3 Fabricated Steel Components ................................................................................. 3 Pile Toes .................................................................................................................. 3 Pile Head Reinforcement ......................................................................................... 3 Main Reinforcement ................................................................................................ 3 Concrete .................................................................................................................. 4 Formwork ................................................................................................................. 4 PRESTRESSING ........................................................................................................ 5 General .................................................................................................................... 5 Concrete Strength ................................................................................................... 5 Post-Tensioned Piles ............................................................................................... 5 Grouting Procedure ................................................................................................. 5 Grout ........................................................................................................................ 6 Records ................................................................................................................... 6 DRIVING PILES .......................................................................................................... 6 Strength of Piles ...................................................................................................... 6 Leaders and Trestles ............................................................................................... 6 Performance of Driving Equipment .......................................................................... 6 Length of Piles ......................................................................................................... 7 Driving Procedure and Redrive Checks................................................................... 7 Final Set .................................................................................................................. 7 Preboring ................................................................................................................. 8 Jetting ...................................................................................................................... 8 RISEN PILES .............................................................................................................. 8 REPAIR AND LENGTHENING OF PILES .................................................................. 8 Repair of Damaged Pile Heads ............................................................................... 8 Lengthening of Reinforced and Prestressed Concrete Piles ................................... 8 Driving Repaired or Lengthened Piles ..................................................................... 8 CUTTING OFF PILE HEADS ...................................................................................... 8 1/9

Section 4 Part 03

General Specification

3. 3.1 3.1.1 1 2

PRECAST REINFORCED AND PRESTRESSED CONCRETE PILES GENERAL Scope This Part applies to precast concrete driven piles usually supplied for use in a single length without facility for joining lengths together. Related Sections and Parts are as follows: This Section Part 1, General requirements for piling concrete Part 2, General requirements for concrete piles Part 9, Static load testing of piles Part 10, Alternative methods for testing piles Part 11, Reduction of friction on piles Section 5, Concrete.

3.1.2 1

References The following Standards are referred to in this Part: ASHTO: LRFD Bridge construction specifications. ASTM A 148/A 148M: Steel Castings, High Strength, for Structural Purposes ASTM A 570/A 570M: Standard Specification for Steel, Sheet and Strip, Carbon, Hot-Rolled, Structural Quality ACI 301 M: Specification for Structural Concrete. ACI 318/318R: Building code requirements for structural concrete.

3.1.3 1

Submittals The Contractor shall order the piles to suit the construction programme and seek the Engineer's approval before placing the order. When preliminary piles are specified, the approval of the piles for the main work will not necessarily be given until the results of the driving and loading tests on preliminary piles have been received and evaluated. Quality Assurance After a pile has been cast, the date of casting, reference number, length and, where appropriate, the prestressing force shall be clearly inscribed on the top surface of the pile and also clearly and indelibly marked on the head of the pile. Lifting positions shall be marked at the proper locations on each pile. Tolerances in Pile Dimensions The cross-sectional dimensions of the pile shall be not less than those specified and shall not exceed them by more than 6 mm. Each face of a pile shall not deviate by more than 6 mm from any straight line 3 m long joining two points on that face, nor shall the centre of area of the pile at any cross section along its length deviate by more than 1/500 of the pile length from a line joining the centres of area at the ends of the pile. Where a pile is less than 3 m long, the permitted

3.1.4 1

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Section 4 Part 03

General Specification

deviation from straightness shall be reduced below 6 mm on a pro rata basis in accordance with actual length. 3.1.6 1 Handling, Transportation and Storage of Piles The method and sequence of lifting, handling, and storage of piles transporting and storing piles shall be such as to avoid shock loading and to ensure that the piles are not damaged. Only the designated lifting and support points shall be used. During transport and storage, piles shall be appropriately supported under the marked lifting points or fully supported along their length. All piles within a stack shall be in groups of the same length. Packing of uniform thickness shall be provided between piles at the lifting points. Concrete shall at no time be subjected to loading, including its own weight, which will induce a compressive stress in it exceeding 0.33 of its strength at the time of loading or of the specified strength, whichever is the lesser. For this purpose the assessment of the strength of the concrete and of the stresses produced by the loads shall be subject to the agreement of the Engineer. A pile may be rejected when the width of any transverse crack exceeds 0.3 mm. The Measurement shall be made with the pile in its working attitude. MATERIALS AND COMPONENTS Fabricated Steel Components In the manufacture of precast concrete piles, fabricated steel components shall comply with ASTM A 570/A 570M, Cast Steel components with ASTM A 148 / A148M.Casing pipes shall confirm to the requirements of section 11 of AASHTO LRFD Bridge Construction Specifications. Pile Toes Pile toes shall be constructed so as to ensure that damage is not caused to the pile during installation. Where positional fixity is required on an inclined rock surface or in other circumstances, an approved shoe may be required. Pile Head Reinforcement The head of each pile shall be so reinforced or banded as to prevent bursting of the pile under driving conditions. Main Reinforcement The main longitudinal reinforcing bars in piles not exceeding 12 m in length shall be in one continuous length unless otherwise specified. In piles more than 12 m long, lap splicing will be permitted in main longitudinal bars at 12 m nominal intervals, with no more than 25 % of the bars lapped at one location, and laps staggered by a minimum of 1.2 m. Laps in reinforcement shall be such that the full strength of the bar is effective across the joint. Lap or splice joints shall be provided with sufficient link bars to resist eccentric forces. Sufficient reinforcement shall be provided for lifting and handling purposes.

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4 3.2 3.2.1 1

3.2.2 1

3.2.3 1 3.2.4 1

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3.2.5 1

Concrete Unless otherwise agreed by the Engineer, concrete shall be compacted with the assistance of vibrators. Internal vibrators shall be capable of producing not less than 150 Hz and external vibrators not less than 50 Hz. Internal vibrators shall operate not closer than 75 mm to shuttering. Vibrators shall be operated in such a manner that neither segregation of the concrete mix constituents nor displacement of reinforcement occurs. Immediately after compaction, concrete shall he adequately protected from the harmful effects of the weather, including wind, rain, rapid temperature changes and frost. It shall be protected from drying out by an approved method of curing. Piles shall not be removed from formwork until a sufficient pile concrete strength has been achieved to allow the pile to be handled without damage. The period of curing at an ambient temperature of 10 C shall not be less than that shown in Table 3.1. If the temperature is greater or less than 10 C, the periods given shall be adjusted accordingly and shall be approved. When steam or accelerated curing is used the curing procedure shall be approved. Four hours must elapse from the completion of placing concrete before the temperature is raised. The rise in temperature within any period of 30 min shall not exceed 10 C and the maximum temperature attained shall not exceed 70 C. The rate of subsequent cooling shall not exceed the rate of heating. Table 3.1 Period of Curing at 10C

2 3

4 5

NO. Type of cement 1 2 3 4 5 Ordinary Portland Sulphate-resisting Portland Portland blast-furnace Super-sulphated

Wet curing time after completion of placing concrete, d 4 4 4 4 3

3.2.6 1

Rapid-hardening Portland Formwork

The head of each pile shall be square to the longitudinal axis. If a pile is constructed with a shaped point or shoe, then the end of the pile shall be symmetrical about the longitudinal axis of the pile. Holes for handling or pitching, where provided in the pile, shall be lined with steel tubes; alternatively, approved inserts may be cast in. Formwork shall be robust, clean and so constructed as to prevent loss of grout or aggregate from the wet concrete and ensure the production of uniform pile sections, free from defects. The piles are to be removed from the formwork carefully so as to prevent damage.

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Section 4 Part 03

General Specification

3.3 3.3.1 1

PRESTRESSING General Tensioning shall be carried out only when the Engineer is present, unless otherwise approved. In cases where piles are manufactured off site, the Contractor shall ensure that the Engineer is given adequate notice and every facility for inspecting the manufacturing process. Prestressing operations shall be carried out only under the direction of an experienced and competent supervisor. All personnel operating the stressing equipment shall have been trained in its use. The calculated extensions and total forces, including allowance for losses, shall be agreed with the Engineer before stressing is commenced. Stressing of tendons and transfer of prestress shall be carried out at a gradual and steady rate. The force in the tendons shall be obtained from readings on a recently calibrated load cell or pressure gauge incorporated in the equipment. The extension of the tendons under the agreed total forces shall be within 5 % of the agreed calculated extension. Concrete Strength The Contractor shall cast sufficient cubes, cured in the same manner as the piles, to be able to demonstrate by testing two cubes at a time, with approved intervals between pairs of cubes, that the specified transfer strength of the concrete has been reached. Unless otherwise permitted, concrete shall not be stressed until two test cylinders attain the specified transfer strength. Post-Tensioned Piles Ducts and vents in post-tensioned piles shall be grouted after the transfer of prestress. Grouting Procedure Grout shall be mixed for a minimum of 2 min and until a uniform consistency is obtained. Ducts shall not be grouted when the air temperature in the shade is lower than 3 C. Before grouting is started all ducts shall be thoroughly cleaned by means of compressed air. Grout shall be injected near the lowest point in the duct in one continuous operation and allowed to flow from the outlet until the consistency is equivalent to that of the grout being injected. Vents in ducts shall be provided in accordance with ACI 318

3.3.2 1

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3.3.5 1

Grout Unless otherwise directed or agreed by the Engineer (a) The grout shall consist only of ordinary Portland cement, water and approved admixtures; admixtures containing chlorides or nitrates shall not be used The grout shall have a water: cement ratio as low as possible consistent with the necessary workability, and the water: cement ratio shall not exceed 0.45 unless an approved mix containing an expanding agent is used The grout shall not be subject to bleeding in excess of 2 % after 3 h, or in excess of 4 % maximum, when measured at 18 C in a covered glass cylinder approximately 100 mm in diameter with a height of grout of approximately 100 mm, and the water shall be reabsorbed after 24 h.

(b)

(c)

3.3.6 1

Records The Contractor shall keep detailed records of times of tensioning, measured extensions, pressure gauge readings or load cell readings and the amount of pull-in at each anchorage. Copies of these records shall be supplied to the Engineer within such reasonable time from completion of each tensioning operation as may be required, and in any case not later than noon on the following working day. The Contractor shall keep records of grouting, including the date, the proportions of the grout and any admixtures used, the pressure, details of interruption and topping up required. Copies of these records shall be supplied to the Engineer within such reasonable time after completion of each grouting operation as may be required, and in any case not later than noon on the following working day. DRIVING PILES Strength of Piles Piles shall not be driven until the concrete has achieved the specified strength. Leaders and Trestles At all stages during driving and until incorporation into the substructure, the pile shall be adequately supported and restrained by means of leaders, trestles, temporary supports or other guide arrangements to maintain position and alignment and to prevent buckling. These arrangements shall be such that damage to the pile does not occur. Performance of Driving Equipment The Contractor shall satisfy the Engineer regarding the suitability, efficiency and energy of the driving equipment. Where designated, dynamic evaluation and analysis shall be provided. Where a drop hammer is used, the mass of the hammer shall be at least half that of the pile unless otherwise approved by the Engineer. For other types of hammer the energy delivered to the pile per blow shall be at least equivalent to that of a drop hammer of the stated mass. Drop hammers shall not be used from floating craft in such a manner as to cause instability of the craft or damage to the pile.

3.4 3.4.1 1 3.4.2 1

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Section 4 Part 03

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3.4.4 1 3.4.5 1

Length of Piles The length of pile to be driven in any location shall be approved prior to the commencement of driving. Driving Procedure and Redrive Checks The driving of each pile shall be continuous until the specified depth or resistance (set), or both, has been reached. In the event of unavoidable interruption to driving, the pile will be accepted provided it can subsequently be driven to the specified depth or resistance (set), or both, without damage. A follower shall not be used unless approved, in which case the Engineer will require the set where applicable to be revised in order to take into account reduction in the effectiveness of the hammer blow. The Contractor shall inform the Engineer without delay if an unexpected change in driving characteristics is noted. A detailed record of the driving resistance over the full length of the nearest available pile shall be taken if required. At the start of the work in a new area or section, a detailed driving record shall be made over the full length of the first pile and during the last 3 m of subsequent piles until consistency of behavior is established. Where required, detailed driving records shall also be made for 5 % of the piles driven, the locations of such piles being specified by the Engineer. The Contractor shall give adequate notice and provide all necessary facilities to enable the Engineer to check driving resistance. A set or resistance measurement shall be taken only in the presence of the Engineer unless otherwise approved. Redrive checks, if required, shall be carried out to an approved procedure. Final Set Piles shall be driven as per section 4 of AASHTO LRFD Bridge construction specifications. They shall be driven to the minimum tip elevations and bearing capacity shown in the contract documents or approved by the engineer. Bearing capacity shall be determined as per AASHTO Specifications. When driving to a set criterion, the final set of each pile shall be recorded either as the penetration in millimetres per 10 blows or as the number of blows required to produce a penetration of 25 mm. When a final set is being measured, the following requirements shall be met: a) b) c) The exposed part of the pile shall be in good condition without damage or distortion The helmet, dolly and any packing shall be in sound condition The hammer blow shall be in line with the pile axis and the impact surfaces shall be flat and at right angles to the pile and hammer axis, and the head of the pile protected against damage from hammer impact The hammer shall be in good condition, delivering adequate energy per blow, and operating correctly The temporary compression of the pile shall be recorded, if required.

5 3.4.6 1

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3.4.7 1

Preboring If preboring is specified, the diameter and depth of prebore shall be as designated.

3.4.8 1 3.5 1 2 3

Jetting Jetting shall be carried out only when the Contractor's detailed proposals have been approved. RISEN PILES Piles shall be driven in an approved sequence to minimize the detrimental effects of heave and lateral displacement of the ground. When required, levels and measurements shall be taken to determine the movement of the ground or of any pile resulting from the driving process. When a pile has risen as a result of adjacent piles being driven, the Engineer may call for redriving or other testing to demonstrate that the performance of the pile is unimpaired. If required, the Contractor shall make proposals for correcting detrimentally affected piles and for avoidance or control of heave effects in subsequent work. REPAIR AND LENGTHENING OF PILES Repair of Damaged Pile Heads If it is necessary to repair the head of a pile during driving, the Contractor shall carry out such repair in an approved way which allows the pile-driving to be completed without further damage. If the driving of a pile has been accepted but sound concrete of the pile is below the required cut-off level, the pile shall be made good to the cut-off level, using an approved method so that it will safely withstand the imposed design load. Lengthening of Reinforced and Prestressed Concrete Piles Any provision for lengthening piles incorporated at the time of manufacture shall be as designed or approved. If no provision for lengthening piles was incorporated at the time of manufacture, any method for lengthening shall be such that splices are capable of safely resisting the stresses during driving and under service load and shall be subject to approval. Driving Repaired or Lengthened Piles Repaired or lengthened piles shall not be driven until the added concrete has reached the specified strength of the concrete of the pile. CUTTING OFF PILE HEADS Unless otherwise directed by the Engineer, when the driving of a pile has been approved the concrete of the head of the pile shall be cut off to the designated level. The length of splice reinforcing bars projecting above this level shall be as designated.

3.6 3.6.1 1

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Section 4 Part 03

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Care shall be taken to avoid shattering or otherwise damaging the rest of the pile. Any cracked or defective concrete shall be cut away and the pile repaired in an approved manner to provide a full and sound section at the cut-off level. END OF PART

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